Project
Modular Knee Brace
Adaptive biomechanical support system for knee stability and recovery
Prototype
Summary
A modular knee brace focused on stability, load distribution, and real-world use. Designed to adapt to different recovery needs.
Use case
Used to support joint stability during training and recovery.
Who it's for
- athletes
- patients
- rehab specialists
Stack
- 3D Printing
- CAD
- Biomechanics
Design deep dive
Problem
Knee instability and pain often come from support that is either too generic or too rigid. Off-the-shelf braces rarely adapt to changing swelling, activity level, or limb geometry, so users trade comfort for stability—or the opposite.
Design
The system is built from modular components and an adjustable structure so fit and support can be tuned without replacing the entire device. The goal is repeatable alignment and load sharing across sessions, not a single fixed geometry.
Engineering considerations
- Force distribution: spread joint-adjacent loads across larger surface areas to reduce pressure hot spots and material fatigue.
- Joint alignment: maintain consistent hinge axis and varus/valgus control relative to the femoral-tibial line during flexion.
- Comfort vs rigidity: calibrate strapping tension and segment stiffness so the brace stays worn during real activity—under-support fails clinically; over-support fails adherence.
Model